Dual protocol stack for maximum speed access to a programmable logic controller (PLC) in a factor automation system

RELATED APPLICATIONS

0001This application is a continuation application of U.S. patent application Ser. No. 09/477,113, filed Dec. 31, 1999 now U.S. Pat. No. 6,587,884, which is a continuation-in-part of U.S. patent application Ser. No. 09/303,458, filed Apr. 30, 1999, now U.S. Pat. No. 6,151,625, which is a continuation-in-part of U.S. patent application Ser. No. 08/927,005, filed Sep. 10, 1997, now U.S. Pat. No. 6,282,454. This application is also related to the following commonly assigned applications entitled “Apparatus for Controlling Internetwork Communications,” U.S. patent application Ser. No. 08/926,837, now U.S. Pat. No. 6,321,272, and “System For A Modular Terminal Input/Output Interface For Communicating Messaging Application Layer Over Encoded Ethernet To Transport Layer,” (amended and originally entitled, “Messaging Application Layer (MODBUS) Over Ethernet To Transport Layer (TCP) Communications Method and Apparatus For a Modular Terminal Input/Output System”), U.S. patent application Ser. No. 09/166,870, now U.S. Pat. No. 6,233,626. The contents of these Applications are expressly incorporated herein by reference.

TECHNICAL FIELD

0002Applicants' invention relates generally to the field of programmable controllers and more particular to a system for coupling a network of programmable controllers through an internetwork to a monitoring and control device.

BACKGROUND OF THE INVENTION

0003Remote monitoring and control of systems and process have taken many forms. In the past, dedicated lines became the most common form of communication between a control system and a remote location. This has limited application since the control system was not accessible from multiple locations. Modems have made it possible to access the control system from different locations, but these types of systems are generally restricted to downloading and uploading data files. Providing any type of control function between locations is rather limited in this type of environment. Further, an end user generally required a customized interface to access the control system.

0004With the growth of Internet, and its World Wide Web providing a deliver platform for organizing Internet data through hypertext links, a client server system can be designed that will give each end user the same type of a user friendly interface with the same universal access to services on the Web. The Web is a network of documents called sites or pages stored on server computers throughout the world Each page will usually contain text, some type of multimedia offerings such as graphic images, video, or audio, and possible hypertext links to other documents. A browser allows a user to read the pages and interact with the choices associated with it. The browser is a graphical software program that sends commands to the Internet Web site and displays whatever information is available on the page. Various browser programs are commercially available from different manufacturers.

0005The Internet network employs methods designed to handle thousands of general purpose computers sharing a single cable, and therefore has no ability to differentiate traffic in terms of its purpose or the critically of its data. The Internet is no longer a network of computers sharing a single cable, but rather a web of interconnected point to point links involving both general purpose stations and specialized infrastructure components such as routers and firewalls.

0006The type of personal computer or work station used by the end user to connect to the Web is of no regard. Communication over the Internet and other networks requires one of several types of protocols. Protocols such as Internet Protocol (IP) provide for file transfers, electronic mail, and other services. A Sun Microsystem programming language known as Java, along with Hypertext Markup Language (HTML) used in designing layouts and graphics for a Web site or page has extended Internet technology such that a web site can be used for dynamic applications, commonly called applets, that can be downloaded and run by the end user. These applets are interpreted and run within a Web browser and have been generally restricted to word processing and similar uses. Downloading and running applets can be slow in comparison to other types of compiled languages. Security rules imposed on a browser and enforced by the underlying JAVA language prevent applets from obtaining certain data from any other device other than the Web server itself.

0007Programmable logic controllers (PLCs) are widely used in industry and process control. Many manufacturers provide factory automation information using Microsoft Windows and other types of communication networking environments. These networks are usually slow, are not universally accessible and are limited to monitoring and data exchange. Control may be implemented, but since the communication networks are non-deterministic, control is not real time. Specialized industrial networks using proprietary fieldbus alternatives can be very expensive. Conversion products are required to allow information carried over those networks to be visible on a general purpose network. There are significant installation and other deployment costs associated with the existence of such intermediate devices. Firewalls between the Web server and the application are designed to solve problems of security and are not designed for high performance.

0008It would be desirable to develop an automation control system whereby an user could use general, commercial networks such as the Internet in place of specialized industrial networks to remotely monitor automation control devices such as PLCs.

0009It is also desirable, as communication networks become faster and more data is interchanged by PLCs in the operation of a control system, to create the fastest method of transporting data possible. The faster the means of communication between a PLC device and its I/O devices the more closely a process can be controlled. Additionally, high speed communication between PLCs can be accomplished to closely couple a distributed control application. However, as data transfer becomes faster improved methods of receiving, processing and transmitting that data must be developed in order to implement it.

SUMMARY OF THE INVENTION

0010Other features and advantages of the invention, which are believed to be novel and nonobvious, will be apparent from the following specification taken in conjunction with the accompanying drawings in which there is shown a preferred embodiment of the invention. Reference is made to the claims for interpreting the full scope of the invention which is not necessarily represented by such embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

0011<figref idref="DRAWINGS">FIG. 1</figref> shows an overview block diagram of a typical system illustrating the relationship between an user at a remote location and an Internet Web site used for monitoring a process control system according to the present invention.

0012<figref idref="DRAWINGS">FIG. 2</figref> is a basic block diagram of the present invention illustrating an Internet interface to a programmable logic controller system.

0013<figref idref="DRAWINGS">FIG. 3</figref> is a block diagram of the Web server module illustrated in <figref idref="DRAWINGS">FIG. 2</figref> according to the present invention.

0014<figref idref="DRAWINGS">FIG. 4</figref> is a typical mimic page available to a user at a remote location utilizing a browser which illustrates the present invention for monitoring a programmable controller system.

DETAILED DESCRIPTION

0015Although this invention is susceptible to embodiments of many different forms, a preferred embodiment will be described and illustrated in detail herein. The present disclosure exemplifies the principles of the invention and is not to be considered a limit to the broader aspects of the invention to the particular embodiment as described.

0016<figref idref="DRAWINGS">FIG. 1</figref> shows an overview block diagram of typical system illustrating the relationship between an user <b>2</b> at a remote location and an Internet web site <b>4</b> used for monitoring a process control system <b>6</b>. The user <b>2</b> will have a personal computer (PC) <b>8</b> having a commercially available browser <b>10</b>, such as Netscape Communication's Navigator or Microsoft's Internet Explorer, installed for viewing the contents at the web site <b>4</b> by a monitor <b>12</b> through a network, such as the Internet <b>14</b>. The PC provides a remote human-machine interface (HMI) to the process control system <b>6</b>. Various interconnection services are readily available to provide the physical and electrical interconnection from the PC to the Internet <b>14</b> itself. The Internet <b>14</b> is a collection of independent world wide communication networks that are interconnected to each other and function as a single connectionless entity. Communication is based on a client-server basis, using a number of established protocols that allow for communication and file transfers between the client and the server. The most widely used protocol is Internet Protocol (IP).

0017The web site <b>4</b> includes a network interface <b>16</b> having an unique Internet address <b>18</b>, a server <b>20</b>, and an application program <b>22</b>. The server <b>20</b> acts as a hypertext transfer protocol (HTTP) interpreter which uses Transmission Control Protocol (TCP) in conjunction with Internet Protocol, through a Transmission Control Protocol/Internet Protocol (TCP/IP) stack <b>24</b> to interact with the network interface <b>16</b> and the application program <b>22</b>. This enables the data transfer between the application program <b>22</b> and the user <b>2</b> through the Internet <b>14</b>. The application program provides data from the process control system <b>6</b>. This data can be used to monitor the control process by the user <b>2</b> at the remote location. The stack <b>24</b> enables data transfers over the Internet <b>14</b> between the user <b>2</b> and the web site <b>4</b> as required for the various layers specified by the IP protocol.

0018The user <b>2</b> can connect to the Internet <b>14</b> using one of a number of Internet service providers and will enter the address of the web site <b>4</b> when connected. The web site <b>4</b> will display a home page which may contain text, some type of multimedia offerings such as graphic images, video, or audio, and possible hypertext links to other documents. The browser <b>10</b> will allow the user <b>2</b> to read the page and interact with the choices associated with it. The browser <b>10</b> will send commands to the web site <b>4</b> which will use the application program <b>22</b> to display whatever information is available from the process control system <b>6</b>. The browser <b>10</b> functions as a remote human-machine interface or HMI control of the process control system as will be detailed below.

0019<figref idref="DRAWINGS">FIG. 2</figref> shows a basic block diagram of the present invention illustrating the Internet interface to a programmable logic controller system. The web site <b>4</b> includes the network interface <b>16</b> having an unique Internet address <b>18</b> and a web server <b>30</b>. The web server <b>30</b> provides the home page for the website. A firewall or security for the overall system can be included in the web server <b>30</b>, but is generally maintained as part of the network interface <b>16</b>. In addition to providing security for various pages at the site, the user can disable the web server <b>30</b>. A password and user list is provided in initial configuration files stored in the web server <b>30</b> that are downloaded from a remote server. Protection of the configuration file is then provided by the remote server and the web server <b>30</b> through the password and the user list. The web server <b>30</b> provides a direct connection for a programmable logic controller (PLC) <b>32</b> to the Internet <b>14</b> by plugging the web server <b>30</b> into its back plane <b>34</b>. The web server <b>30</b> provides both a client and server interface. All signals between the PLC <b>32</b> and the web server <b>30</b> are through the back plane <b>34</b> rather than over a set of cables which would normally have to be coupled to input/output modules that are themselves plugged into the back plane <b>34</b>. The back plane signals include addressing, control, data, and power. The client interface allows a user to send commands to a remote node over the Internet and the server interface allows for processing commands that originated from a remote node. Controlling the PLC <b>32</b> from a remote HMI, essentially on a real time basis is possible by controlling the data flow through the web server <b>30</b>.

0020Associated with the PLC <b>32</b> are its application programs <b>36</b>, dual port memory <b>38</b> and Input/Output (I/O) modules <b>40</b>. The application programs <b>36</b> include a ladder logic program for controlling the I/O modules <b>40</b>. The web server <b>30</b> functions as a node on a TCP/IP network <b>42</b> allowing it to send commands to the PLC <b>32</b> and receive the response. Although the TCP/IP network <b>42</b> in the preferred embodiment is an Ethernet network, other high level protocols could be used. Using a web browser at a remote location through the Internet <b>14</b>, a user can control and view configuration information of the PLC <b>32</b>.

0021The web server <b>30</b> is shown in greater detail in FIG. <b>3</b>. Various components provide the required connectivity to perform its functionality. A real time operating system <b>44</b> controls the interaction between the components. The operating system <b>44</b> allocates processor time on a central processor unit (CPU) <b>46</b> to various tasks, provides memory management, and provides a set of message services and signal services. The message and signal services allow for communication between tasks, and between drivers and a task.

0022Connection to the TCP/IP network <b>42</b> is through an Ethernet driver <b>48</b> which transmits and receives messages at a rate of 100 Mbs (megabits per second) or faster via an Ethernet communication chip <b>49</b>, such as, in the case of 100 Mbs Ethernet, a Crystal CS8952 available from Cirrus Logic, Inc. It is contemplated that in the future Ethernet communication chips capable of speeds of 1 Gbs (gigabits per second) and faster can be used. The physical connection over which communication is facilitated can be over a fiber optic cable or a twisted pair-type copper wire. However, the physical connection must be capable of transmitting the signal at 100 Mbs or faster. In the case of 100 Mbs Ethernet over twisted pair-type copper wire, the copper wire and wire connections must conform to at least the Category 5 copper wire standard.

0023Alternatively, the TCP/IP stack <b>24</b> could be replaced by a dual TCP/IP stack. The dual TCP/IP stack comprises a first TCP/IP stack which provides support for a broad range of TCP/IP messages. The first stack is preferably a standard SENS stack from Wind River, Inc., although any commercially available TCP/IP stack is adaptable to the present invention. The second TCP/IP stack is a “short stack” which manages high priority control messages between the PLC <b>32</b> and I/O modules <b>40</b>. The second stack is optimized to handle very specific TCP/IP messages, in this instance Modbus on Ethernet, in order to process the specific message in the most efficient manner possible.

0024For outgoing TCP/IP messages, the appropriate TCP/IP stack would be chosen by an application program <b>36</b> associated with the PLC <b>32</b>. On incoming TCP/IP messages, the TCP/IP message would be intercepted and examined to see if: 1) it is a TCP/IP message, 2) that is intended for the Modbus on Ethernet protocol (i.e. is the source protocol the Internet Assigned Number for the Modbus on Ethernet Protocol of 502), and 3) is the destination port above a specified number (3072). If it is a TCP/IP message intended for the Modbus on Ethernet protocol, then the message is delivered to the second stack. If it is not a TCP/IP message intended for the Modbus on Ethernet protocol, the first TCP/IP stack handles the message. In this manner, TCP/IP messages intended for the Modbus on Ethernet protocol are handled more quickly and efficiently than when a single TCP/IP stack is implemented.

0025The web server will have an unique global address <b>18</b>, allowing it to be addressed by other devices on the network. The Ethernet driver <b>48</b> manages transmit <b>50</b> and receive <b>51</b> buffers in memory <b>52</b>, and interfaces with the Ethernet communication chip <b>49</b>. The transmit <b>50</b> and receive <b>51</b> buffers are shared both by the Ethernet communication chip <b>49</b> and the Ethernet driver <b>48</b>. The Ethernet driver <b>48</b> also provides a transmit request interface and a receive indication interface to a TCP/IP stack <b>54</b>. The Ethernet communication chip <b>49</b> provides a transmit queue interface, a receive queue interface, and generates interrupts on completion of transmitting a message, and on receiving a new message. The Ethernet driver <b>46</b> places receive buffers in the receive queue. In the interrupt routine, the Ethernet driver <b>46</b> examines the receive queue. If any messages are in the receive queue, it passes the receive buffer to the TCP/IP stack <b>54</b>. The TCP/IP stack <b>54</b> copies the buffer, and sometime later calls the Ethernet driver <b>48</b> to return the buffer and place the returned buffer back into the receive queue.

0026The TCP/IP stack <b>54</b> calls the Ethernet driver <b>48</b> to transmit a message. The Ethernet driver <b>46</b> attempts to allocate a buffer from the shared memory <b>52</b>. If it succeeds, it copies the message into the buffer, and places the buffer into the Ethernet communication chip <b>49</b> transmit queue. If there is no transmit buffer, then the driver drops the transmit message. In the interrupt routine, the Ethernet driver <b>48</b> examines the transmit queue, and frees the transmitted buffers.

0027The TCP/IP network <b>42</b> allows special MSTR (master) functions that allow nodes on the network to initiate message transactions. These MSTR functions include reading and writing data and are used for commands and responses. They allow programs running in the PLC <b>32</b> to send commands to a remote node on the TCP/IP network <b>42</b> and receive the responses. A back plane driver <b>56</b> sends commands and receives the response to the PLC <b>32</b> over the back plane <b>34</b>.

0028The back plane driver <b>56</b> receives request from the PLC's ladder logic MSTR blocks stored in its memory <b>38</b>. When a response is available, the back plane driver <b>56</b> passes it back to the MSTR block. The back plane driver <b>56</b> provides a client task <b>58</b> and server task <b>60</b> to the applications. The server task <b>60</b> interface allows an application to issue a request command to the PLC's <b>32</b> executive program and receive its response. The client task <b>58</b> allows an application to receive a new MSTR request and pass back the response to the ladder logic program.

0029The server task <b>60</b> uses a queuing mechanism and call back functions. An application queues both the request and the call back function associated with the request. When the back plane driver <b>56</b> services the request in its interrupt routine, it calls the associated call back function. The response and the original request is passed to the call back function. The call back function can call an operating routine to either pass a message or signal the application.

0030The client task <b>58</b> also uses queues and call back functions. The client application queues both an indication request on queue and a call back function associated with the request. When the back plane driver <b>56</b> detects a new MSTR block request in its interrupt routine, it calls the associated call back function. The request is passed into the call back function. The call back function can call an operating system routine to either pass a message or signal the application. If the back plane driver <b>56</b> detects that the MSTR block has been aborted, or is no longer being solved, it calls an user supplied associated abort call back function. The application calls a routine to pass the MSTR response and an associated call back routine to the driver. Sometime later, the driver passes back the response to the ladder logic program in its interrupt service routine, and then calls the user supplied call back function.

0031The PLC <b>32</b> interfaces with the web server <b>30</b> hardware via the dual port memory <b>38</b>. It reads and writes to the dual port memory <b>38</b> using an ASIC chip. Writing to a specified location will cause an interrupt. The PLC <b>32</b> first writes a message in the dual port memory <b>38</b>, and then causes an interrupt. The message indicates a type of command. One type indicates that a MSTR block is being solved. Other types are used for passing requests to the PLC <b>32</b> and obtaining the responses to the requests. After the PLC <b>32</b> passes the message, it polls the dual port memory <b>38</b> for commands placed by the back plane driver <b>56</b>. These commands are read memory, write memory, and processing is complete. The back plane driver <b>56</b> uses state machines to process the MSTR interrupts. The maximum number of active MSTR blocks is set at four in the present invention, requiring four state machines. When the back plane driver <b>56</b> receives a MSTR interrupt, it attempts to find an associated state machine that matches with the MSTR block. If there are already four outstanding transactions, no more are available, and the back plane driver <b>56</b> will set the MSTR's outputs to false. If a state machine is found, the back plane driver <b>56</b> determines if it is a new transaction, an outstanding transaction, or a response is available. If it is a new transaction it copies the request and calls the application's associated call back routine. If its an outstanding transaction, it indicates to the ladder logic program that the MSTR block is still busy. If a response is available, the back plane driver <b>56</b> copies the response, sets either the MSTR's completion or error output, and calls the application's call back routine.

0032Two interrupts are used for processing a request. On the first interrupt, called the preport interrupt, the back plane driver <b>56</b> copies the request into a data structure located in the PLC's <b>32</b> dual memory <b>38</b>. On the second interrupt, called the end of scan interrupt, the back plane driver <b>56</b> copies the response from the controller's data structure into the user's buffer. It then calls the user's associated call back function.

0033The request for accessing the PLC's <b>32</b> registers is processed by the back plane driver <b>56</b> and is not sent to the PLC's executive program for processing. The back plane driver <b>56</b> determines the memory location in the memory <b>38</b> of the registers the PLC <b>32</b>. At an end of scan interrupt, the back plane driver <b>56</b> processes the read/write register requests by sending commands via the dual port memory <b>38</b> to the PLC <b>32</b> to read or write the locations containing the registers. The back plane driver <b>56</b> will service a maximum of four read/write register requests at the end of a scan interrupt.

0034A client task <b>58</b> interfaces with the TCP/IP stack <b>54</b>, the back plane driver <b>56</b> and uses the operating system <b>44</b> message services. It processes the MSTR request. When the client task <b>58</b> receives a MSTR request from the back plane driver <b>56</b>, it passes the request to the TCP/IP stack <b>54</b>. When the TCP/IP stack <b>54</b> returns a response to the client task <b>58</b>, it passes the response to the back plane driver <b>56</b>. The TCP/IP stack <b>54</b> provides a Berkeley TCP/IP interface and a signal extension. The signal extension calls a user supplied function which passes in a socket number, a task ID, and an event. The signal function calls the operating system <b>44</b> to send a message to the task indicated by the task ID. It sends a message either to the client task <b>58</b> or server task <b>60</b>. The client task <b>58</b> posts request indications to the back plane driver <b>56</b>, and the associated call back routine calls the operating system <b>44</b> to send a message to the client task <b>58</b> for a new MSTR transaction.

0035The client task <b>58</b> manages multiple outstanding MSTR transactions using the state machines. There is a linked list of connection state machines. The connection state machines are used for establishing connection and closing connections. In addition each connection state machine contains a list of transaction state machines. Each transaction machine on the connection state machine represents a transaction to a node represented by the connection machine. The transaction machines are used to send a request, and process the response. The client task <b>58</b> enters a loop after performing initialization. It calls the operating system <b>44</b> to receive a message. The operating system will block the client task <b>58</b> until there is a message or until there is a time out. It either receives a message from the TCP/IP stack <b>54</b>, from a MSTR call back routine, or it times out. It process the message or the time out and then reenters the loop. If the message received from the operating system <b>44</b> is a new MSTR request, the client task will obtain a connection state machine, and places a new transaction machine at end of the list of the connection state machine's list. At this point the transaction machine will attempt to transmit the message. It may not be possible to transmit the message because no connection has been established, or the because the remote side may have applied flow control.

0036If the message received from the operating system <b>44</b> is a TCP/IP event, the client task <b>58</b> finds the associated connection machine and determines if the TCP/IP event is an accepted connection, an aborted connection, or a received data event. Based on the connection state, and the transaction machine's state, the client task <b>58</b> processes the message to advance the transactions if there are any. Receiving data for the MSTR responses may occur over several TCP/IP events, and the transaction state machine assembles the data into a response. When the client task <b>58</b> requests the TCP/IP stack to transmit a message, not all of the message may be transmitted. This occurs when the remote node is flow controlled, which is explained below. If the call to the operating system <b>44</b> to receive a message returns with a time out, or if there is a message, the client task <b>58</b> searches the list of connection machines that are flowed controlled. For each flow controlled connection, it tries to advance the transaction state machines on the connection state machine list that are flow controlled.

0037The server task <b>60</b> processes a request originating from the user at the remote location. The server task <b>60</b> interfaces with the back plane driver <b>56</b>, the TCP/IP stack <b>54</b>, and the operating system's <b>44</b> message services. The server task <b>60</b> posts requests to the back plane driver <b>56</b>, and an associated call back routine uses the operating system <b>44</b> message services to send the response to the server task <b>60</b>. A TCP/IP stack <b>54</b> signal function also uses the operating system's <b>44</b> send service to send an TCP/IP event to the server task <b>60</b>. The server task <b>60</b> can handle multiple transactions and connections. Like the client task <b>58</b>, it maintains a list of connection machines, and each connection machine contains a list of transaction machines. The connection machines are for managing the connection and the transaction machines manage the incoming requests and responses.

0038The server task <b>60</b> enters a loop after performing initialization. It calls the operating systems <b>44</b> to receive a message. The operating systems <b>44</b> block the server task <b>60</b> until there is a message or until it times out. It either receives a message from the TCP/IP task's <b>54</b> signal handler, from the back plane driver <b>56</b> or it times out. It processes the message or the time and reenters the loop. If the message received from the operating systems <b>44</b> is from the TCP/IP task's <b>54</b> signal handler, the server task <b>60</b> determines if the event is a connection request, a close socket event, or a receive data event. Based on the TCP/IP event, the server task <b>60</b> uses the connection machine and transaction machine to advance the transaction. Received data for a request may occur over several receive data events, and the transaction machine assembles the events into a request message. When the response message is received from the operating system <b>44</b>, the server task <b>60</b> finds the connection and transaction machine in order to send the response.

0039When the server task <b>60</b> requests the TCP/IP stack <b>54</b> to transmit a message, not all of the message may be transmitted. This occurs when the remote node is flow controlled. If the call to the operating system <b>44</b> is to receive a message returns with a time out, or if there is a message, the server task <b>54</b> searches the list of connection machines that are flowed controlled. For each flow controlled connection, it tries to advance the transaction state machines on the connection state machine list that are flow controlled.

0040After the server task <b>60</b> has parsed the header of an incoming request, it attempts to allocate a structure to pass the request to the back plane driver <b>56</b>. If the server task is already processing a predetermined number of outstanding requests, the attempt fails, the connection is placed into a blocked state, and the body of the request is not read from the TCP/IP stack <b>54</b>. As a result the TCP/IP stack may apply flow control to the remote node. When one of the other requests is complete, the free data structure event causes a blocked connection machine to continue processing the incoming Modbus request.

0041The HTTP task <b>62</b> interfaces with the TCP/IP stack <b>54</b>, and the back plane driver <b>56</b>. The HTTP server task <b>62</b> receives a HTTP request from the TCP/IP stack <b>54</b>. To process the request, it may access the PLC <b>32</b> through the back plane driver <b>56</b> and back plane <b>34</b>. The HTTP server task <b>62</b> sends back the response over the TCP/IP stack <b>54</b>. The framework is supplied by the operating system <b>44</b>. The framework creates the HTTP task, accepts connection, and parses the HTTP request. After parsing the request, it calls the operating system <b>44</b> to process the request. Processing the request involves determining the request type and processing the actual request. The different request types allow a user to acquire a snapshot of the PLC <b>32</b> operations by allowing a view of various registers within the PLC <b>32</b> and dual memory <b>38</b>. These request types also include display of the PLC <b>32</b> configuration, remote and distributed I/O and module health statistics, display registers, back plane configuration, Ethernet statistics and others, as shown in Table 1:

0042<tables id="TABLE-US-00001" num="00001"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="2"><colspec colname="offset" colwidth="14pt" align="left" /><colspec colname="1" colwidth="203pt" align="left" /><thead><row><entry /><entry namest="offset" nameend="1" rowsep="1">TABLE 1</entry></row><row><entry /><entry namest="offset" nameend="1" align="center" rowsep="1" /></row></thead><tbody valign="top"><row><entry /><entry>Show the home page</entry></row><row><entry /><entry>Show the programmable logic controller's configuration</entry></row><row><entry /><entry>Show the Ethernet statistics</entry></row><row><entry /><entry>Show the read register request page</entry></row><row><entry /><entry>Show the 4× registers</entry></row><row><entry /><entry>Show the racks attached to the controllers back plane</entry></row><row><entry /><entry>Send an image. The different images are gif files that are</entry></row><row><entry /><entry>displayed on the various pages</entry></row><row><entry /><entry>Show the remote I/O statistics</entry></row><row><entry /><entry>Show the list of configured remote I/O drops</entry></row><row><entry /><entry>Show a remote I/O rack's configuration and health</entry></row><row><entry /><entry>Show a remote I/O drop's communication statistics</entry></row><row><entry /><entry>Show the I/O reference values of a remote I/O module</entry></row><row><entry /><entry>Show a list of configured distributed I/O nodes</entry></row><row><entry /><entry>Show the configuration and the health of a distributed I/O node</entry></row><row><entry /><entry>Show the I/O reference values of a distributed I/O module</entry></row><row><entry /><entry namest="offset" nameend="1" align="center" rowsep="1" /></row></tbody></tgroup></table></tables>

0043The home page contains hyperlinks to seven pages of data. The configuration page will display the configuration of PLC <b>32</b>. The remote I/O and distributed I/O module health status pages are a series of linked pages. The first page displays the communication health statistics at the Remote I/O and Distributed I/O head and contains a link to a configured drop page. The configured drop page displays a table containing drop numbers which are linked to a drop status page and rack numbers which are linked to the drop and rack configuration pages. Two tables are included in the drop status page, one for showing the communication status of the drop and the other for showing which racks are populated with the I/O modules. The drop and rack configuration page displays the I/O modules, their health, and slot location for the given rack. From a selected module, a user can view it's input and output values. Register data is displayed in a template having a form and a table, with the user entering an address and a length. The table will display the register's values A table showing option modules and their slot location is displayed on the back plane configuration page. The data appearing on the pages is static but can be automatically updated at preselected times.

0044The operating system <b>44</b> processes these requests and responds by sending HTTP messages through the TCP/IP stack <b>54</b>. Processing some of these requests involves reading the PLC's traffic cop, registers, coils, or various page zero locations where statistics are kept. To perform these reads, the operating system <b>44</b> sends a request to the back plane driver <b>56</b> and uses an event signal mechanism and event flags to determine when the request is complete. After sending the request to the back plane driver <b>56</b>, the operating system <b>44</b> waits for an event flag to be sent. When the back plane driver completes the request, the back plane driver <b>56</b> calls a call back routine, which sets the event. The operating system <b>44</b> then resumes processing the request.

0045A mimic page which represents some of the hardware physically connected to a programmable logic controller system can be constructed utilizing various graphical programs readily available and that are not an object of the present invention. The present invention allows a user at a remote location, using a browser, to view the mimic page and actually control various components illustrated in the mimic page. <figref idref="DRAWINGS">FIG. 4</figref> shows a simple motor start-stop control in ladder logic diagram form that could be available as a mimic page to the user. Pushing a motor start push button <b>150</b> will cause a motor start relay <b>152</b> to energize through a normally closed stop push button <b>154</b> and a normally closed overload contact <b>156</b>. Auxiliary motor start contact <b>158</b> will latch relay <b>152</b> after the start push button <b>150</b> is released and pilot light <b>160</b> will illuminate. Auxiliary motor start contact <b>162</b> will provide power to pump motor <b>164</b> which will remain running until stop push button <b>154</b> is depressed or overload relay <b>166</b> detects an overload condition. In this example, start push button <b>150</b>, stop push button <b>154</b>, overload contact <b>156</b>, auxiliary motor start contacts <b>158</b> and <b>162</b>, and overload relay <b>166</b> are inputs to the programmable logic controller system. Relay <b>152</b>, pilot light <b>160</b>, and pump motor <b>164</b> are outputs. The PLC will have the registers containing the animation data for the inputs and outputs. An application program in the PLC will respond to the inputs to control the outputs

0046A user at a remote location will browse the Internet for the home page of the installation of the programmable logic controller system. The PLC will have other control functions as well and if the user has the necessary authorizations, various options will become available. The home page will allow the user to acquire a snapshot of the PLC operations by allowing a view of various pages that will allow access to registers within the PLC. Other pages will also include displays of the PLC's configuration, remote and distributed I/O modules health statistics, display registers, back plane configuration, Ethernet statistics and others as shown previously shown in Table 1.

0047The mimic diagram page will be called up on a browser screen which will allow the user to view the status of the system. The mimic diagram's light <b>160</b>, relay <b>152</b>, contacts <b>158</b>, <b>162</b>, and pump motor <b>164</b> will be updated to correspond to the state of the actual devices. The states of the inputs and outputs will then be shown on the ladder diagram which will be automatically updated as they are changed. Through the use of applets representing the start <b>150</b> and stop <b>154</b> buttons, the user could manually control start and stopping of the motor by using a mouse or keyboard to position a cursor and “clicking” on either the start <b>168</b> or stop <b>170</b> boxes.

0048While the specific embodiments have been illustrated and described, numerous modifications are possible without departing from the scope or spirit of the invention.